Structure for and method of constructing trim dies

ABSTRACT

A cast trim die section having a base part of metal which can be readily machined to facilitate fastening the die section to a die carrier and having a rim part of hardenable metal for trimming metal stampings, which die section is formed by simultaneously pouring the metals having dissimilar properties into a mold at different points, to cast the base part and rim part as the molten metals approach each other in the mold and to form a hot fused joint between the base and rim part of the die on filling of the mold. Two or more such die sections set end to end, which die sections are positioned to provide an inverted V-shaped cross section, may be simultaneously cast from a separate two-compartment crucible having openings coded to correspond to different cross section mold sprues. The castings may be formed with risers on flat lands at the intersection of the base and rim parts which can be flame cut from the finished castings.

[4 1 Jan. 21, 1975 1 STRUCTURE FOR AND METHOD OF CONSTRUCTING TRIM DIES [75] Inventor: Charles C. Mezey, Rochester, Mich.

[73] Assignee: Full Mold Process, lnc., Lathrup Village, Mich.

[22] Filed: Aug. 7, 1972 [21] Appl. No.: 278,462

[52] US. Cl 164/93, 164/246, 164/244, 164/34 [51] Int. Cl B22d 23/00 [58] Field of Search 164/96, 93, 246, 34, 35, 164/36, 244; 75/20 F, 20

[56] References Cited UNITED STATES PATENTS 473,466 4/1892 Kennedy et a1 164/93 945,019 1/1910 Connell l v 164/93 3,157,924 11/1964 Smith 164/D1G. 1 3,259,949 7/1966 Moore 164/34 3,295,175 1/1967 Krzyzanowski 164/246 3,452,806 7/1969 Wittmoser 164/246 FOREIGN PATENTS OR APPLICATIONS 10,274 8/1901 Great Britain 164/93 164,877 12/1949 Austria 164/96 740,827 10/1943 Germany 164/96 Primary ExaminerFrancis S. Husar Assistant ExaminerV. K. Rising Attorney, Agent, or Firm-Whittcmore, Hulbert & Belknap [57] ABSTRACT A cast trim die section having a base part of metal which can be readily machined to facilitate fastening the die section to a die carrier and having a rim part of hardenable metal for trimming metal stampings, which die section is formed by simultaneously pouring the metals having dissimilar properties into a mold at different points, to cast the base part and rim part as the molten metals approach each other in the mold and to form a hot fused joint between the base and rim part of the die on filling of the mold.

Two or more such die sections set end to end. which die sections are positioned to provide an inverted V-shaped cross section, may be simultaneously cast from a separate two-compartment crucible having openings coded to correspond to different cross section mold sprues. The castings may be formed with risers on flat lands at the intersection of the base and rim parts which can be flame cut from the finished castings.

10 Claims, 4 Drawing Figures PATENTEDJANZI 191s FIG.2

FIG.4

STRUCTURE FOR AND METHOD OF CONSTRUCTING TRIM DIES BACKGROUND OF THE INVENTION 1. Field of the Invention The invention relates to integrally cast trim die sections and the manufacture thereof and refers more specifically to a trim die section having relatively perpendicularly extending cross section base and rim parts simultaneously cast of metals having dissimilar properties such as mild steel and tool steel, which parts are connected by fusing of the molten metals at the joint between the parts during casting of the die section.

2. Description of the Prior Art In the past, trim dies, or more particularly trim die sections which are well known in the metal stamping art, have included a base part built up of bar stock of a mild steel which is easily machinable an a rim part built up of bar stock of tool steel which may be hardened to provide a cutting edge. In such trim die sections, the base part has been connected to the rim part by means of an arc weld between the base part and rim part. This welding operation is undesirable in that it re quires expensive equipment for welding the particularly heavy joints required in trim die sections.

In the past, it has been suggested that trim die sections be cast entirely of the mild steel in a mold wherein a cutting edge or rim portion has been inserted. Attempts to produce trim die sections in such manner has resulted in warped die sections due to the dissimilar shrinkage between the cast mild steel and the tool steel inserts.

It has also been suggested in the past to place easily machinable inserts in a mold and cast the major portion of the trim die sections of hardenable tool steel, after which the mild steel could be machined to provide openings for attaching bolts, aligning dowels, and the like. Trim die sections produced in such manner, however, have resulted in loose inserts and so have also been unacceptable.

SUMMARY OF THE INVENTION In accordance with the present invention, a die section is produced by simultaneously pouring the dissimilar mild steel and tool steel into separate sprues in a single mold, which sprues are located in a position so that the rim part of the trim die section which is to be sharpened for use as a cutting edge is formed of the tool steel, while the base part of the trim die section which is to be machined to facilitate securing the die section to a die carrier is formed of the mild steel, and a hot fused joint is formed between the mild and tool steels during casting in an area which it is unnecessary to use as a cutting edge or to machine.

One, two or more such trim die sections, having an L-shaped cross section, may be cast in a single mold with the cross section of the die sections forming an inverted V in the mold on pouring the metals having the different characteristics through separate sprues and gates extending to the ends of the trim die sections at the lowest point of the base and trim parts of the inverted V-shaped cross sections, which sprues are of different cross section and are coded to correspond to separate pouring openings in a single crucible having .two separate compartments therein containing the different molten metals.

In manufacturing such trim die sections, risers are provided at the apex of the inverted V-shaped cross section on flat lands so that the risers may be easily flame cut from the finished castings. The finished castings may also have rough bolt and dowel pin openings therein as well as recesses and openings therethrough for reducing the machining required and the weight thereof in accordance with the required strength.

Also, in producing trim die sections in accordance with the invention. it is possible to use the Shroyer method of casting trim die sections using expanded polystyrene or any other vaporizable material which vaporizes, leaving substantially no residue on pouring of hot metal into a properly made mold. For the details of the use of the expendable patterns, the Shroyer Pat. No. 2,830,343 is referred to.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a trim die section constructed in accordance with the method of the invention.

FIG. 2 is an end view of a trim die section such as that shown in FIG. I in use.

FIG. 3 is a cross section view of a trim die section such as that shown in FIG. 1 in mold structure used in casting the trim die section in accordance with the method of the invention, which cross section view is taken substantially on the line 3-3 in FIG. 4.

FIG. 4 is a partial cross section view of the mold structure illustrated in FIG. 3 taken substantially on the line 4-4 in FIG. 3 showing full trim die mold forms and blind risers in the mold structure.

DESCRIPTION OF THE PREFERRED EMBODIMENT The trim die section 10 illustrated in FIG. 1 is generally L-shaped in cross section and includes a base part 12 and a rim part 14. The base part 12 of the die section 10 is cast of mild steel which is easily machinable to permit securing of the base part 12 to a die carrier 16 by convenient means such as bolts 18, and dowel pins 20, as shown in FIG. 2. The rim part 14 is cast of tool steel which may be hardened and sharpened to provide a cutting edge 22 for shearing metal from door panels 24 or the like formed between stemping dies 26 and 28, as shown in FIG. 2. The parts 12 and 14 of the trim die section 10 are fused at the time of casting at the intersection 25 of the parts which are cast simultaneously.

More particularly, the base part 12 of the trim die section 10, constructed in accordance with the invention, is generally rectangular in cross section and has the counterbored openings 30 extending therethrough as required to receive the bolts 18 which in assembly of the trim die section 10 to die carrier 16 are passed through the openings 30 and threaded into recesses 32 in the die carrier. Openings 34 are further provided extending through the base part 12 of the trim die section 10 through which aligning dowels 20 are inserted into recesses 36 in the die carrier 16.

The surface 38 of the base part 12 of the die section 10 may be machined over its entirety or may be recessed as desired to provide a desired bearing surface on the die carrier 16 and may be recessed and of a thickness required to provide necessary strength for a particular trim die application.

The rim part 14 of the trim die section may be cast with openings 40 extending therethrough or may be otherwise recessed to provide required strength for the trim die section 10 with a minimum of metal. The rim part 14 of the trim die section 10 as cast is provided with a portion 23 on which the cutting edge 22 is machined.

In manufacture, the trim die section 10 is cast of two dissimilar metals which may be non-ferrous combinations as well as ferrous combinations such as the mild steel and tool steel indicated above. The mild steel and tool steel are simultaneously poured into a mold 42, as shown best in FIG. 3, to provide a hot fused joint between the two molten metals substantially at the apex 70 of the L-shaped cross section.

As shown in FIG. 3, the mold 42 includes the cope 46 and drag 44 when conventional molding technics are used. A single plain box may be used in the Shroyer full mold process.

Two sprues 56 and 58 having pouring basins 60 and 62, respectively, at the outer ends thereof are formed in the sand 52 and connect with the lower ends 64 and 66, respectively, of the base and trim parts of the mold form 50 through gates 65 and 67. The sprues 56 and 58 may have different cross section such as, for example, round for the sprue 56 and square for the sprue 58. Thus, two different metals poured simultaneously into the sprues 56 and 58 from a two-compartment crucible having pouring spouts therein aligned with the sprues and coded to correspond to the sprues should always be poured into the right gates.

The blind risers 68 shaped as shown are provided at the apex 70 of the mold form 50 for the particular rim die section 10. The risers 68 are set on flat lands 72 in the form 50 whereby metal flowing into the risers 68 during casting may be flame cut from the trim die section 10. The risers 68 provide continued flow of the metals during fusing thereof to insure complete fusing of the metals.

As shown best in FIG. 4, two trim die sections 10 may be east through the two sprues 56 and 58. The two die sections 10 are east end to end and are similar in all respects.

As pointed out above, forming the trim die sections 10 by simultaneously pouring a mild steel in the mold sprue 56 to form the base part 12 and pouring a tool steel in the mold sprue 58 to form the rim part 14, which steels merge in a hot fusion where the base part and rim part meet eliminates the need for a welded, two-part die section made from bar stock and the relatively expensive arc welding process formerly use, particularly on large, heavy trim die sections.

While one embodiment of the invention has been considered in detail, it will be understood that other embodiments and modifications are contemplated by the inventor. Thus, while a trim die section having a particular configuration has been shown and described, it will be understood that complete trim dies and die sections having other configurations may be constructed in accordance with the invention. It is the intention to include all such embodiments and modifications as are defined by the appended claims within the scope of the invention.

What I claim as my invention is:

l. The method of manufacture comprising casting two molten metals having dissimilar properties in different portions of a mold simultaneously to flow the molten metals toward each other and form a fusion therebetween at the intersection thereof whereby an integral casting'is formed having parts with different properties, which casting is a trim die section which is substantially L-shaped in cross section to provide base and trim parts and is cast in a mold formed by a die pattern positioned in the mold to form an inverted V in cross section, providing flat portions at the apex of the die pattern used to form the die section, and building riser patterns from the flat portions of the die pattern whereby risers are formed on the die section during casting which risers may be easily flame cut from the die section across similar flat portions on the die section, and gating the mold at the ends of the die section at the low ends of both parts of the cross section thereof whereby the metals flow toward the apex of the inverted L-shaped cross section to form the fusion therebetween at substantially the apex of the L-shaped cross section.

2. The method as set forth in claim 1 wherein two or more trim die sections are cast simultaneously with adjacent ends which adjacent ends are gated from the same sprues and gates.

3. The method as set forth in claim 2 and further including forming the cross sections for the sprues for the dissimilar metals with different cross sections for identification.

4. The method as set forth in claim 1 and further including placing a pattern shaped in the form of the tinished casting desired in the mold, which pattern is constructed of material which vaporizes substantially without residue on pouring of hot metal into the mold.

5. The method as set forth in claim 4 wherein blind risers are provided in the mold to permit continuous flow of the metalsduring fusion thereof as the mold is filled.

6. The method of manufacture comprising placing a pattern shaped in the form of the finished casting desired to be cast in a mold, which pattern is constructed of material which vaporizes substantially without residue upon pouring of hot metal into the mold. casting two molten metals having dissimilar properties in different portions of the mold simultaneously to flow the molten metals toward each other and form a fusion therebetween at the intersection thereof whereby an integral casting is formed having parts with different properties.

7. The method as set forth in claim 6 and further providing blind risers in the mold to permit continuous flow of the metals during fusion thereof as the mold is filled.

8. The method as set forth in claim 6 wherein the casting is a trim die section which is substantially L- shaped in cross section to provide base and trim parts and is positioned in the mold to form an inverted V in cross section and gating the mold at the ends of the die section at the low ends of both parts of the cross section thereof whereby the metals flow toward the apex of the inverted L-shaped cross section to form the fusion therebetween substantially at the apex of the L-shaped cross section.

9. The method as set forth in claim 8 and further including simultaneously casting two or more trim die sections with adjacent ends, and gating the adjacent ends from the same sprues and gates.

10. The method as set forth in claim 7 and further including providing sprues for the dissimilar metals with different cross sections for identification. 

1. The method of manufacture comprising casting two molten metals having dissimilar properties in different portions of a mold simultaneously to flow the molten metals toward each other and form a fusion therebetween at the intersection thereof whereby an integral casting is formed having parts with different properties, which casting is a trim die section which is substantially L-shaped in cross section to provide base and trim parts and is cast in a mold formed by a die pattern positioned in the mold to form an inverted V in cross section, providing flat portions at the apex of the die pattern used to form the die section, and building riser patterns from the flat portions of the die pattern whereby risers are formed on thE die section during casting which risers may be easily flame cut from the die section across similar flat portions on the die section, and gating the mold at the ends of the die section at the low ends of both parts of the cross section thereof whereby the metals flow toward the apex of the inverted L-shaped cross section to form the fusion therebetween at substantially the apex of the L-shaped cross section.
 2. The method as set forth in claim 1 wherein two or more trim die sections are cast simultaneously with adjacent ends which adjacent ends are gated from the same sprues and gates.
 3. The method as set forth in claim 2 and further including forming the cross sections for the sprues for the dissimilar metals with different cross sections for identification.
 4. The method as set forth in claim 1 and further including placing a pattern shaped in the form of the finished casting desired in the mold, which pattern is constructed of material which vaporizes substantially without residue on pouring of hot metal into the mold.
 5. The method as set forth in claim 4 wherein blind risers are provided in the mold to permit continuous flow of the metals during fusion thereof as the mold is filled.
 6. The method of manufacture comprising placing a pattern shaped in the form of the finished casting desired to be cast in a mold, which pattern is constructed of material which vaporizes substantially without residue upon pouring of hot metal into the mold, casting two molten metals having dissimilar properties in different portions of the mold simultaneously to flow the molten metals toward each other and form a fusion therebetween at the intersection thereof whereby an integral casting is formed having parts with different properties.
 7. The method as set forth in claim 6 and further providing blind risers in the mold to permit continuous flow of the metals during fusion thereof as the mold is filled.
 8. The method as set forth in claim 6 wherein the casting is a trim die section which is substantially L-shaped in cross section to provide base and trim parts and is positioned in the mold to form an inverted V in cross section and gating the mold at the ends of the die section at the low ends of both parts of the cross section thereof whereby the metals flow toward the apex of the inverted L-shaped cross section to form the fusion therebetween substantially at the apex of the L-shaped cross section.
 9. The method as set forth in claim 8 and further including simultaneously casting two or more trim die sections with adjacent ends, and gating the adjacent ends from the same sprues and gates.
 10. The method as set forth in claim 7 and further including providing sprues for the dissimilar metals with different cross sections for identification. 